Vapor disposition of silicon-containing films using penta-substituted disilanes

ABSTRACT

Disclosed are methods of depositing silicon-containing films on one or more substrates via vapor deposition processes using penta-substituted disilanes, such as pentahalodisilane or pentakis(dimethylamino)disilane.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.15/459,158, filed Mar. 15, 2017, which is a divisional of U.S. patentapplication Ser. No. 14/979,816, filed Dec. 28, 2015 and matured togrant as U.S. Pat. No. 9,633,838, the entire contents of which areincorporated herein by reference.

TECHNICAL FIELD

Disclosed are methods of depositing silicon-containing films on one ormore substrates via vapor deposition processes using penta-substituteddisilanes, such as pentachlorodisilane orpentakis(dimethylamino)disilane.

BACKGROUND

Silicon-containing films are one of the most important components insemiconductor devices and development of their various fabricationprocesses has been highly investigated. Silicon oxide (SiO₂) films maybe used as capacitor and insulating layers. D. Tahir et al., “Electronicand optical properties of Al₂O₃/SiO₂ films grown on Si substrate”, J.Phys. D: Appl. Phys. 43, 255301 (2010). Silicon nitride (SiN), siliconcarbide (SiC) and silicon carbonitride (SiCN) films may be used as hardmask, diffusion barriers or trench etch-stop layers. Si-Yi Li et al.,“Selectivity Control in Plasma Etching for Dual Damascene with OSGfilms”, Abstract #242, 199^(th) ECS Meeting (2001); Ping Xu et al., “ABreakthrough in Low-k Barrier/Etch Stop Films for Copper DamasceneApplications”, Semiconductor FABTECH, 11, 239 (2000); Y. L. Wang et al.,“Integration of SiCN as a Low k Etch Stop and Cu Passivation in a HighPerformance Cu/Low k Interconnect”, Materials 5, 377-384 (2012).

Use of pentachlorodisilane (PCDS or Si₂HCl₅) andpentakis(dimethylamino)disilane (Si₂H(NMe₂)₅) as vapor depositionprecursors has been described in the prior art. See, e.g., US2004/224089to Singh et al., WO2007/112780 to Dussarrat, and US2008/026149 toTomasini et al.

However, it remains a challenge to find silicon-containing precursorssuitable for commercial deposition of silicon-containing films.

SUMMARY

Disclosed are vapor deposition processes for the deposition ofsilicon-containing films on substrates. The vapor of a Si-containingfilm forming precursor is introduced into a reactor containing thesubstrate. The Si-containing film forming composition comprises apenta-substituted disilane precursor. At least part of thepenta-substituted disilane film forming precursors is deposited onto thesubstrate to form the silicon-containing film. The disclosed processesmay further include one or more of the following aspects:

-   -   The penta-substituted disilane precursor being        pentachlorodisilane (PCDS or Si₂HCl₅);    -   The penta-substituted disilane precursor being pentaiododisilane        (Si₂HI₅);    -   The penta-substituted disilane precursor being        pentabromodisilane (Si₂HBr₅);    -   The penta-substituted disilane precursor being        pentafluorodisilane (Si₂HF₅);    -   The penta-substituted disilane precursor being        pentakis(dimethylamino)disilane [Si₂H(NMe₂)₅];    -   the Si-containing film forming composition comprising between        approximately 99% w/w and approximately 100% w/w of the        penta-substituted disilane precursor;    -   the Si-containing film forming composition comprising between        approximately 95% w/w and approximately 100% w/w of the        penta-substituted disilane precursor;    -   the Si-containing film forming composition comprising between        approximately 0% w/w and approximately 5% w/w impurities;    -   the Si-containing film forming composition comprising between        approximately 0.0% w/w and approximately 2.0% w/w impurities;    -   the Si-containing film forming composition comprising between        approximately 0.0% w/w and approximately 1.0% w/w impurities;    -   the impurities including hexa-, tetra-, and tris-substituted        disilanes having the formula Si₂H_(x)X_(y), wherein X═Cl, Br, I,        or NR₂, R═H or a C1-C4 alkyl group, x=0, 2, or 3, and x+y=6;        tetra-substituted silanes having the formula SiX₄, wherein X═Cl,        Br, I, or NR₂, and R═H or a C1-C4 alkyl group; tris-substituted        silanes having the formula SiHX₃, wherein X═Cl, Br, I, or NR₂,        and R═H or a C1-C4 alkyl group; partially substituted trisilanes        having the formula Si₃H_(x)X_(y), wherein X═Cl, Br, I, or NR₂,        R═H or a C1-C4 alkyl group, x+y=8 and x=1 to 6; siloxanes having        the formula SiHX2—O—SiX₃, wherein X═Cl, Br, I, or NR₂, and R═H        or a C1-C4 alkyl group; siloxanes having the formula        H_(x)X_(y)Si—O—SiH_(x)X_(y), wherein X═Cl, Br, I, or NR₂, R═H or        a C1-C4 alkyl group, x=0, 2, or 3, and x+y=3; siloxanes having        the formula SiH_(x)X_(y)—O—SiH_(x)X_(y), wherein X═Cl, Br, I, or        NR₂, R═H or a C1-C4 alkyl group hydrogen, x+y=3, and x=0 or 1;        siloxanes having the formula H_(x)X_(y)Si—O—(Si₂H_(a)X_(b)),        wherein X═Cl, Br, I, or NR₂, R═H or a C1-C4 alkyl group, x+y=3,        a+b=6, x=1 to 3, and a=0, 2, or 3; siloxanes having the formula        H_(x)X_(y)Si—O—SiH_(a)X_(b)—O—SiH_(x)X_(y), wherein X═Cl, Br, I,        or NR₂, R═H or a C1-C4 alkyl group, x+y=3, a+b=2, x=1 to 3, and        a=0 to 2; iodine; bromine; chlorine; dialkylamines, such as        dimethylamine or ethylamine; THF; ether; pentane; hexane;        cyclohexane; heptanes; benzene; toluene; or combinations        thereof;    -   the Si-containing film forming composition comprising between        approximately 0.0% w/w and approximately 1.0% w/w        hexa-substituted disilanes having the formula Si₂X₆, wherein        X═Cl, Br, I, or NR₂, R═H or a C1-C4 alkyl group;    -   the Si-containing film forming composition comprising between        approximately 0.0% w/w and approximately 1.0% w/w        tetra-substituted disilanes having the formula Si₂H₂X₄, wherein        X═Cl, Br, I, or NR₂, R═H or a C1-C4 alkyl group;    -   the Si-containing film forming composition comprising between        approximately 0.0% w/w and approximately 1.0% w/w        tris-substituted disilanes having the formula Si₂H₃X₃, wherein        X═Cl, Br, I, or NR₂, R═H or a C1-C4 alkyl group;    -   the Si-containing film forming composition comprising between        approximately 0.0% w/w and approximately 1.0% w/w        tetra-substituted silanes having the formula SiX₄, wherein X═Cl,        Br, I, or NR₂, and R═H or a C1-C4 alkyl group;    -   the Si-containing film forming composition comprising between        approximately 0.0% w/w and approximately 1.0% w/w        tris-substituted silanes having the formula SiHX₃, wherein X═Cl,        Br, I, or NR₂, and R═H or a C1-C4 alkyl group;    -   the Si-containing film forming composition comprising between        approximately 0.0% w/w and approximately 1.0% w/w partially        substituted trisilanes having the formula Si₃H_(x)X_(y), wherein        X═Cl, Br, I, or NR₂, R═H or a C1-C4 alkyl group, x+y=8, and x=1        to 6;    -   the Si-containing film forming composition comprising between        approximately 0.0% w/w and approximately 1.0% w/w siloxanes        having the formula SiHX₂—O—SiX₃, wherein X═Cl, Br, I, or NR₂,        and R═H or a C1-C4 alkyl group;    -   the Si-containing film forming composition comprising between        approximately 0.0% w/w and approximately 1.0% w/w siloxanes        having the formula H_(x)X_(y)Si—O—SiH_(x)X_(y), wherein X═Cl,        Br, I, or NR₂, R═H or a C1-C4 alkyl group, x=0, 2, or 3, and        x+y=3;    -   the Si-containing film forming composition comprising between        approximately 0.0% w/w and approximately 1.0% w/w siloxanes        having the formula SiH_(x)X_(y)—O—SiH_(x)X_(y), wherein X═Cl,        Br, I, or NR₂, R═H or a C1-C4 alkyl group hydrogen, x+y=3, and        x=0 or 1;    -   the Si-containing film forming composition comprising between        approximately 0.0% w/w and approximately 1.0% w/w siloxanes        having the formula H_(x)X_(y)Si—O—(Si₂H_(a)X_(b)), wherein X═Cl,        Br, I, or NR₂, R═H or a C1-C4 alkyl group, x+y=3, a+b=5, x=1 to        3, and a=0, 2, or 3;    -   the Si-containing film forming composition comprising between        approximately 0.0% w/w and approximately 1.0% w/w siloxanes        having the formla H_(x)X_(y)Si—O—SiH_(a)X_(b)—O—SiH_(x)X_(y),        wherein X═Cl, Br, I, or NR₂, R═H or a C1-C4 alkyl group, x+y=3,        a+b=2, x=1 to 3, and a=0 to 2;    -   the Si-containing film forming composition comprising between        approximately 0.0% w/w and approximately 1.0% w/w dialkylamines,        such as dimethylamine or ethylamine;    -   the Si-containing film forming composition comprising between        approximately 0.0% w/w and approximately 1.0% w/w THF;    -   the Si-containing film forming composition comprising between        approximately 0.0% w/w and approximately 1.0% w/w ether;    -   the Si-containing film forming composition comprising between        approximately 0.0% w/w and approximately 1.0% w/w pentane;    -   the Si-containing film forming composition comprising between        approximately 0.0% w/w and approximately 1.0% w/w hexane;    -   the Si-containing film forming composition comprising between        approximately 0.0% w/w and approximately 1.0% w/w cyclohexane;    -   the Si-containing film forming composition comprising between        approximately 0.0% w/w and approximately 1.0% w/w heptanes;    -   the Si-containing film forming composition comprising between        approximately 0.0% w/w and approximately 1.0% w/w benzene;    -   the Si-containing film forming composition comprising between        approximately 0.0% w/w and approximately 1.0% w/w toluene;    -   the Si-containing film forming composition comprising between        approximately 0 ppbw and approximately 1 ppmw metal impurities;    -   the Si-containing film forming composition comprising between        approximately 0 ppbw and approximately 500 ppbw metal        impurities;    -   The vapor deposition process being an atomic layer deposition        (ALD) process;    -   The vapor deposition process being a chemical vapor deposition        (CVD) process;    -   Further comprising introducing an oxidant into the reactor;    -   The oxidant being O₂, O₃, H₂O, H₂O₂, NO, N₂O, NO₂, carboxylic        acids, formic acid, acetic acid, propionic acid, oxygen        containing radicals thereof, or mixtures thereof;    -   The oxidant being O₂, O₃, H₂O, oxygen containing radicals        thereof, or mixtures thereof;    -   The oxidant being O₂, O₃, oxygen containing radicals thereof, or        mixtures thereof;    -   The oxidant being a 7.2% v/v mixture of O₃in O_(2;)    -   The silicon-containing film being silicon oxide;    -   The silicon oxide film having a wet etch rate less than or equal        to ten times the wet etch rate of silicon oxide deposited by        thermal deposition using a dilute HF solution (0.5 to 1% HF);    -   The silicon oxide film being deposited at a temperature ranging        from approximately 450° C. to approximately 800° C.;    -   The ALD process depositing a silicon oxide film at a temperature        ranging from approximately 550° C. to approximately 600° C.;    -   The thermal ALD process depositing a silicon oxide film at a        temperature ranging from approximately 100° C. to approximately        400° C.;    -   The plasma ALD process depositing a silicon oxide film at a        temperature ranging from approximately room temperature to        approximately 400° C.;    -   The silicon oxide film containing between approximately 0 atomic        % and approximately 5 atomic % carbon;    -   The silicon oxide film containing between approximately 0 atomic        % and approximately 2.5 atomic % carbon;    -   The silicon oxide film containing between approximately 0 atomic        % and approximately 1 atomic % carbon;    -   The silicon oxide film containing between approximately 0 atomic        % and approximately 1 atomic % nitrogen;    -   The silicon oxide film containing between approximately 0 atomic        % and approximately 1 atomic % chlorine;    -   Silicon oxide film exhibiting step coverage between        approximately 70% and approximately 100% for an aspect ratio of        1:7;    -   Silicon oxide film exhibiting step coverage between        approximately 70% and approximately 100% for an aspect ratio of        1:20;    -   Silicon oxide film exhibiting step coverage between        approximately 90% and approximately 100% for an aspect ratio of        1:7;    -   Silicon oxide film exhibiting step coverage between        approximately 90% and approximately 100% for an aspect ratio of        1:20;    -   Further comprising introducing a nitrogen-containing reactant        into the reactor;    -   The nitrogen-containing reactant being NH₃, N₂H₄, N(SiH₃)₃,        N(CH₃)H₂, N(C₂H₅)H₂, N(CH₃)₂H, N(C₂H₅)₂H, N(CH₃)₃, N(C₂H₅)₃,        (SiMe₃)₂NH, (CH₃)HNNH₂, (CH₃)₂NNH₂, nitrogen-containing radical        species thereof, and mixtures thereof;    -   The nitrogen-containing reactant being NH₃;    -   The silicon-containing film being silicon nitride;    -   The silicon nitride film being deposited at a temperature        ranging from approximately 450° C. to approximately 650° C.;    -   The silicon nitride film having a refractivity index that ranges        from approximately 1.7 to approximately 2.2;    -   Further comprising introducing an amine, an alkylaminosilane, or        a disilazane into the reactor;    -   The amine being ammonia;    -   The alkylaminosilane being bis(diethylamino)silane;    -   The alkylaminosilane being tris(dimethylamino)silane;    -   The disilazane being hexamethyldisilazane;    -   The silicon containing film being a carbon doped silicon nitride        film;    -   The carbon doped silicon nitride film having a carbon        concentration ranging from approximately 5 atomic % to        approximately 40 atomic %;    -   The carbon doped silicon nitride film having a nitrogen        concentration ranging from approximately 20 atomic % to        approximately 60 atomic %;    -   The carbon doped silicon nitride film having an oxygen        concentration ranging from approximately 0 atomic % to        approximately 5 atomic %;    -   The process being a plasma enhanced atomic layer deposition        (PEALD) process;    -   Further comprising introducing a nitrogen-containing reactant        into the reactor;    -   The nitrogen-containing reactant being N₂, NH₃, N₂H₄, N(SiH₃)₃,        N(CH₃)H₂, N(C₂H₅)H₂, N(CH₃)₂H, N(C₂H₅)₂H, N(CH₃)₃, N(C₂H₅)₃,        (SiMe₃)₂NH, (CH₃)HNNH₂, (CH₃)₂NNH₂, a mixture of N₂ and H₂,        nitrogen-containing radical species thereof, and mixtures        thereof;    -   The nitrogen-containing reactant being NH₃, N₂, a mixture of N₂        and H₂, and mixtures thereof;    -   The mixture of N₂ and H₂ containing between approximately 0% v/v        to approximately 70% v/v H₂;    -   The mixture of N₂ and H₂ containing approximately 50% v/v H₂;    -   The silicon containing film being a carbon doped silicon nitride        film;    -   The PEALD process depositing a carbon doped silicon nitride film        at a temperature ranging from approximately 100° C. to        approximately 350° C.;    -   The carbon doped silicon nitride film having a refractive index        ranging from approximately 1.6 to approximately 2.1; and    -   The carbon doped silicon nitride film having a carbon        concentration ranging from approximately 1 atomic % to        approximately 15 atomic %.

Also disclosed are processes for the vapor deposition of silicon carbidefilms on one or more substrates. The vapor of a silicon-containing filmforming composition comprising is introduced into a reactor containingthe substrate(s). The silicon-containing film forming compositionscomprises a silicon halide. At least part of the silicon halide isdeposited onto the substrate(s) to form the silicon carbide film. Analkyl substituted metal or metalloid is introduced into the reactor. Atleast part of the alkyl substituted metal or metalloid is deposited ontothe substrate to form the silicon carbide film. The disclosed processesmay further include one or more of the following aspects:

-   -   the Si-containing film forming composition comprising between        approximately 99% w/w and approximately 100% w/w of the silicon        halide;    -   the Si-containing film forming composition comprising between        approximately 95% w/w and approximately 100% w/w of the silicon        halide;    -   the Si-containing film forming composition comprising between        approximately 0% w/w and approximately 5% w/w impurities;    -   the Si-containing film forming composition comprising between        approximately 0.0% w/w and approximately 2.0% w/w impurities;    -   the Si-containing film forming composition comprising between        approximately 0.0% w/w and approximately 1.0% w/w impurities;    -   the impurities including hexa-substituted disilanes;        alkylamines; dialkylamines; alkylimines; iodosilanes;        aminosilanes; lithium, sodium, or potassium iodide; iodine; THF;        ether; pentane; cyclohexane; heptanes; benzene; toluene;        halogenated metal compounds;    -   the Si-containing film forming composition comprising between        approximately 0 ppbw and approximately 1 ppmw metal impurities;    -   the Si-containing film forming composition comprising between        approximately 0 ppbw and approximately 500 ppbw metal        impurities;    -   The silicon halide containing at least one halogen atom;    -   The silicon halide containing at least one silicon-halogen bond;    -   The silicon halide having the formula SiX₄, each X independently        being Cl, Br, I, H, or R and R being an aliphatic group;    -   The silicon halide being SiCl₃H;    -   The silicon halide being SiH₂Cl₂;    -   The silicon halide being SiH₃Cl;    -   The silicon halide being SiI₂H₂;    -   The silicon halide being SiHMeI₂;    -   The silicon halide being SiMe₂I₂;    -   The silicon halide being SiH_(x)Cl_(3-x)(CH₂Cl), with x=0-3;    -   The silicon halide being SiH₃(CH₂Cl);    -   The silicon halide being SiH₂Cl(CH₂Cl);    -   The silicon halide being SiHCl₂(CH₂Cl);    -   The silicon halide being SiCl₃(CH₂Cl);    -   The silicon halide having the formula Si₂X₆, with each X        independently being Cl, Br, I, or H;    -   The silicon halide being pentachlorodisilane;    -   The silicon halide being pentabromodisilane;    -   The silicon halide being pentaiododisilane;    -   The silicon halide being pentafluorodisilane;    -   The silicon halide being hexachlorodisilane;    -   The silicon halide being hexaiododisilane;    -   The silicon halide being monochlorodisilane;    -   The silicon halide being monobromodisilane;    -   The silicon halide being monoiododisilane;    -   The silicon halide being 1,1-dichlorodisilane [Cl₂HSi—SiH₃];    -   The silicon halide being dibromodisilane [H₂BrSi—SiBrH₂];    -   The silicon halide being diiododisilane [H₂ISi—SiIH₂];    -   The silicon halide being dichlorodisilane [H₃Si—SiHCl₂];    -   The silicon halide being dibromodisilane [H₃Si—SiHBr₂];    -   The silicon halide being diiododisilane [H₃Si—SiHI₂];    -   The silicon halide having the formula X₃Si—CH₂—SiX₃, with each X        independently being Cl, Br, I, or H;    -   The silicon halide being bis(dichlorosilyl)methane        [(SiCIH₂)₂CH₂];    -   The silicon halide being monochlorotrisilapentane        [H₃Si—CH₂—SiH₂Cl];    -   The silicon halide having the formula X₃Si—CH₂—CH₂—SiX₃, with        each X independently being Cl, Br, I, or H;    -   The silicon halide having the formula X₃Si—CH₂—SiX₂—CH₂—SiX₃,        with each X independently being Cl or H, provided at least one        terminal X is Cl;    -   The silicon halide having the formula Cl₃Si—CH₂—SiCl₂—CH₂—SiCl₃;    -   The silicon halide having the formula H₃Si—CH₂—SiH₂—CH₂—SiClH₂;    -   The silicon halide having the formula (—SiX₂—CH₂—)₃, with each X        independently being Cl, Br, or I;    -   The silicon halide having the formula (—SiHX—CH₂—)₃, with each X        independently being Cl, Br, or I;    -   The silicon halide being octachlorotrisilane (OCTS);    -   The silicon halide being decachlorotetrasilane (Si₄Cl₁₀);    -   The silicon halide being dodecachloropentasilane (DCPS or        Si₅Cl₁₂);    -   The alkyl substituted metal or metalloid having the formula        AlR₃, with each R independently being H, Me, Et, nPr, iPr, nBu,        iBu, or NR₂, provided that when R₃═H₃ that the molecule may be        adducted with an amine or borohydride;    -   The alkyl substituted metal or metalloid being triethyl        aluminum;    -   The alkyl substituted metal or metalloid being trimethyl        aluminum;    -   The alkyl substituted metal or metalloid being AlH₃.NH₃;    -   The alkyl substituted metal or metalloid having the formula BR₃,        with each R independently being an alkyl or an allyl group;    -   The alkyl substituted metal or metalloid being triethyl boron;    -   The alkyl substituted metal or metalloid being trimethyl boron;    -   The alkyl substituted metal or metalloid having the formula        AlClR₂, with each R independently being H, Me, Et, nPr, iPr,        nBu, or iBu, or NR₂;    -   The alkyl substituted metal or metalloid having the formula        BXR₂, with X being Cl, Br, or I and each R independently being        an alkyl or an allyl group;    -   The alkyl substituted metal or metalloid having the formula        ZnR₂, with each R independently being Me, Et, nPr, iPr, nBu, or        iBu;    -   The alkyl substituted metal or metalloid having the formula        GaR₃, with each R independently being Me, Et, nPr, iPr, nBu,        iBu, or NR₂;    -   The alkyl substituted metal or metalloid being trimethyl        gallium; and    -   The alkyl substituted metal or metalloid having the formula        InR₃, with each R independently being Me, Et, nPr, iPr, nBu,        iBu, or NR₂.

Also disclosed is a Si-containing film forming composition deliverydevice comprising a canister having an inlet conduit and an outletconduit and containing any of the Si-containing film formingcompositions disclosed above. The disclosed device may include one ormore of the following aspects:

-   -   the Si-containing film forming composition having a total        concentration of metal contaminants of less than 10 ppmw;    -   an end of the inlet conduit end located above a surface of the        Si-containing film forming composition and an end of the outlet        conduit located below the surface of the Si-containing film        forming composition;    -   an end of the inlet conduit end located below a surface of the        Si-containing film forming composition and an end of the outlet        conduit located above the surface of the Si-containing film        forming composition;    -   further comprising a diaphragm valve on the inlet and the        outlet;    -   further comprising one or more barrier layers on an interior        surface of the canister;    -   further comprising one to four barrier layers on an interior        surface of the canister;    -   further comprising one or two barrier layers on an interior        surface of the canister;    -   each barrier layer comprising a silicon oxide layer, a silicon        nitride layer, silicon oxynitride layer, a silicon carbonitride,        silicon oxycarbonitride layer, or combinations thereof;    -   wherein each barrier layer is 5 to 1000 nm in thickness;    -   wherein each barrier layer is 50 to 500 nm in thickness;    -   the Si-containing film forming composition comprising        pentachlorodisilane (PCDS or Si₂HCl₅);    -   the Si-containing film forming composition comprising        pentaiododisilane (Si₂HI₅);    -   the Si-containing film forming composition comprising        pentabromodisilane (Si₂HBr₅);    -   the Si-containing film forming composition comprising        pentafluorodisilane (Si₂HF₅);    -   the Si-containing film forming composition comprising        pentakis(dimethylamino)disilane [Si₂H(NMe₂)₅];    -   The Si-containing film forming composition comprising SiCl₃H;    -   The Si-containing film forming composition comprising SiH₂Cl₂;    -   The Si-containing film forming composition comprising SiH₃Cl;    -   The Si-containing film forming composition comprising SiI₂H₂;    -   The Si-containing film forming composition comprising SiHMeI₂;    -   The Si-containing film forming composition comprising SiMe₂I₂;    -   The Si-containing film forming composition comprising        SiH_(x)Cl_(3-x)(CH₂Cl), with x=0-3;    -   The Si-containing film forming composition comprising        SiH₃(CH₂Cl);    -   The Si-containing film forming composition comprising        SiH₂Cl(CH₂Cl);    -   The Si-containing film forming composition comprising        SiHCl₂(CH₂Cl);    -   The Si-containing film forming composition comprising        SiCl₃(CH₂Cl);    -   The Si-containing film forming composition comprising a silicon        halide having the formula Si₂X₆, with each X independently being        Cl, Br, I, or H;    -   The Si-containing film forming composition comprising        pentachlorodisilane;    -   The Si-containing film forming composition comprising        pentabromodisilane;    -   The Si-containing film forming composition comprising        pentaiododisilane;    -   The Si-containing film forming composition comprising        pentafluorodisilane;    -   The Si-containing film forming composition comprising        hexachlorodisilane;    -   The Si-containing film forming composition comprising        hexaiododisilane;    -   The Si-containing film forming composition comprising        monochlorodisilane;    -   The Si-containing film forming composition comprising        monobromodisilane;    -   The Si-containing film forming composition comprising        monoiododisilane;    -   The Si-containing film forming composition comprising        1,1-dichlorodisilane [Cl₂HSi—SiH₃];    -   The Si-containing film forming composition comprising        dibromodisilane [H₂BrSi—SiBrH₂];    -   The Si-containing film forming composition comprising        diiododisilane [H₂ISi—SiIH₂];    -   The Si-containing film forming composition comprising        dichlorodisilane [H₃Si—SiHCl₂];    -   The Si-containing film forming composition comprising        dibromodisilane [H₃Si—SiHBr₂];    -   The Si-containing film forming composition comprising        diiododisilane [H₃Si—SiHI₂];    -   The Si-containing film forming composition comprising a silicon        halide having the formula X₃Si—CH₂—SiX₃, with each X        independently being Cl, Br, I, or H;    -   The Si-containing film forming composition comprising        bis(dichlorosilyl)methane [(SiClH₂)₂CH₂];    -   The Si-containing film forming composition comprising        monochlorotrisilapentane [H₃Si—CH₂—SiH₂Cl];    -   The Si-containing film forming composition comprising a halide        having the formula X₃Si—CH₂—CH₂—SiX₃, with each X independently        being Cl, Br, I, or H;    -   The Si-containing film forming composition comprising a silicon        halide having the formula X₃Si—CH₂—SiX₂—CH₂—SiX₃, with each X        independently being Cl or H, provided at least one terminal X is        Cl;    -   The Si-containing film forming composition comprising a silicon        halide having the formula Cl₃Si—CH₂—SiCl₂—CH₂—SiCl₃;    -   The Si-containing film forming composition comprising a silicon        halide having the formula H₃Si—CH₂—SiH₂—CH₂—SiClH₂;    -   The Si-containing film forming composition comprising a silicon        halide having the formula (—SiX₂—CH₂—)₃, with each X        independently being Cl, Br, or I;    -   The Si-containing film forming composition comprising a silicon        halide having the formula (—SiHX—CH₂—)₃, with each X        independently being Cl, Br, or I;    -   The Si-containing film forming composition comprising        octachlorotrisilane (OCTS);    -   The Si-containing film forming composition comprising        decachlorotetrasilane (Si₄Cl₁₀); and    -   The Si-containing film forming composition comprising        dodecachloropentasilane (DCPS or Si₅Cl₁₂).

NOTATION AND NOMENCLATURE

Certain abbreviations, symbols, and terms are used throughout thefollowing description and claims, and include:

As used herein, the indefinite article “a” or “an” means one or more.

As used herein, the terms “approximately” or “about” mean ±10% of thevalue stated.

As used herein, the term “independently” when used in the context ofdescribing R groups should be understood to denote that the subject Rgroup is not only independently selected relative to other R groupsbearing the same or different subscripts or superscripts, but is alsoindependently selected relative to any additional species of that same Rgroup. For example in the formula MR¹ _(x) (NR²R³)_((4-x)), where x is 2or 3, the two or three R¹ groups may, but need not be identical to eachother or to R² or to R³. Further, it should be understood that unlessspecifically stated otherwise, values of R groups are independent ofeach other when used in different formulas.

As used herein, the term “alkyl group” refers to saturated functionalgroups containing exclusively carbon and hydrogen atoms. Further, theterm “alkyl group” refers to linear, branched, or cyclic alkyl groups.Examples of linear alkyl groups include without limitation, methylgroups, ethyl groups, propyl groups, butyl groups, etc. Examples ofbranched alkyls groups include without limitation, t-butyl. Examples ofcyclic alkyl groups include without limitation, cyclopropyl groups,cyclopentyl groups, cyclohexyl groups, etc.

As used herein, the abbreviation, “Me,” refers to a methyl group; theabbreviation, “Et,” refers to an ethyl group; the abbreviation, “Pr,”refers to a propyl group; the abbreviation, “iPr,” refers to anisopropyl group; the abbreviation “Bu” refers to butyl; the abbreviation“tBu” refers to tert-butyl; and the abbreviation “sBu” refers tosec-butyl.

Please note that the films or layers deposited, such as silicon oxide orsilicon nitride, may be listed throughout the specification and claimswithout reference to their proper stoichiometry (i.e., SiO₂, SiO₃,Si₃N₄). The layers may include pure (Si) layers, carbide (Si_(o)C_(p))layers, nitride (Si_(k)N_(l)) layers, oxide (Si_(n)O_(m)) layers, ormixtures thereof, wherein k, l, m, n, o, and p inclusively range from 1to 6. For instance, silicon oxide is Si_(n)O_(m), wherein n ranges from0.5 to 1.5 and m ranges from 1.5 to 3.5. More preferably, the siliconoxide layer is SiO₂ or SiO₃. The silicon oxide layer may be a siliconoxide based dielectric material, such as organic based or silicon oxidebased low-k dielectric materials such as the Black Diamond II or IIImaterial by Applied Materials, Inc. Alternatively, any referencedsilicon-containing layer may be pure silicon. Any silicon-containinglayers may also include dopants, such as B, C, P, As and/or Ge.

Any and all ranges recited herein are inclusive of their endpoints(i.e., x=1 to 4 includes x=1, x=4, and x=any number in between).

The standard abbreviations of the elements from the periodic table ofelements are used herein. It should be understood that elements may bereferred to by these abbreviations (e.g., Mn refers to manganese, Sirefers to silicon, C refers to carbon, etc.).

BRIEF DESCRIPTION OF THE FIGURES

For a further understanding of the nature and objects of the presentinvention, reference should be made to the following detaileddescription, taken in conjunction with the accompanying figures wherein:

FIG. 1 is a side view of one embodiment of the Si-containing filmforming composition delivery device disclosed herein;

FIG. 2 is a side view of a second embodiment of the Si-containing filmforming composition delivery device disclosed herein;

FIG. 3 is a schematic diagram of the vapor deposition apparatus used forthe testing in all of the Examples except Example 10;

FIG. 4(a) is a X-ray Photoelectron Spectroscopy (XPS) depth profile ofthe Si film resulting from thermal decomposition of PCDS atapproximately 400° C.;

FIG. 4(b) is a XPS depth profile of the Si film resulting from thermaldecomposition of PCDS at approximately 500° C.;

FIG. 4(c) is a XPS depth profile of the Si film resulting from thermaldecomposition of PCDS at approximately 600° C.;

FIG. 4(d) is a XPS depth profile of the Si film resulting from thermaldecomposition of PCDS at approximately 700° C.;

FIG. 5(a) is a XPS depth profile of the Si film resulting from thermaldecomposition of HCDS at approximately 400° C.;

FIG. 5(b) is a XPS depth profile of the Si film resulting from thermaldecomposition of HCDS at approximately 500° C.;

FIG. 5(c) is a XPS depth profile of the Si film resulting from thermaldecomposition of HCDS at approximately 600° C.;

FIG. 5(d) is a XPS depth profile of the Si film resulting from thermaldecomposition of HCDS at approximately 700° C.;

FIG. 6 is a graph of the average ALD deposition rate in Angstroms/cycleof SiO₂ films deposited using PCDS (circles) or HCDS (triangles) andozone versus temperatures ranging from approximately 500° C. toapproximately 700° C.;

FIG. 7 is a graph of the average ALD growth rate in Angstroms/cycle ofSiO₂ films using PCDS and ozone at approximately 600° C. (squares) orapproximately 550° C. (diamonds) versus PCDS pulse duration in seconds;

FIG. 8(a) is a XPS depth profile of the SiO₂ film resulting from ALDdeposition using PCDS and ozone on a Si substrate at approximately 500°C.;

FIG. 8(b) is a XPS depth profile of the SiO₂ film resulting from ALDdeposition using PCDS and ozone on a Si substrate at approximately 600°C.;

FIG. 8(c) is a XPS depth profile of the SiO₂ film resulting from ALDdeposition using PCDS and ozone on a Si substrate at approximately 650°C.;

FIG. 8(d) is a XPS depth profile of the SiO₂ film resulting from ALDdeposition using PCDS and ozone on a Si substrate at approximately 700°C.;

FIG. 9 is a scanning electronic microscope (SEM) picture showing stepcoverage of an SiO₂ film deposited on a deep hole pattern wafer havingan aspect ratio of 40:1 by 350 ALD cycles using PCDS and ozone atapproximately 600° C.;

FIG. 9(a) is an enlarged SEM picture showing the SiO₂ step coverage atthe top of the structure of FIG. 9;

FIG. 9(b) is an enlarged SEM picture showing the SiO₂ step coverage atthe middle of the structure of FIG. 9;

FIG. 9(c) is an enlarged SEM picture showing the SiO₂ step coverage atthe bottom of the structure of FIG. 9;

FIG. 10 is a graph of the average ALD deposition rate in Angstroms/cycle(diamond) and refractive index (square) of SiO₂ films deposited usingPCDS (circles) or HCDS (triangles), water, and triethylamine versustemperatures ranging from approximately 50° C. to approximately 100° C.;

FIG. 11 is a XPS depth profile of the silicon oxide film resulting fromALD deposition using PCDS, water, and TEA;

FIG. 12 is a graph of the average CVD deposition rate inAngstroms/minute (hollow) and refractive index (filled) of SiN filmsdeposited using PCDS (circle) and HCDS (square) and NH₃ versustemperatures ranging from approximately 450° C. to approximately 600°C.;

FIG. 13 is a graph of the average ALD deposition rate in Angstroms/cycle(hollow) and refractive index (filled) of SiN films deposited using PCDS(circle), HCDS(square), and octachlorotrisilane (triangle) and NH3versus temperature ranging from approximately 350° C. to approximately600° C.;

FIG. 14 is a XPS depth profile for the SiN film deposited at 600° C.with PCDS and NH₃;

FIG. 15 is a XPS depth profile of the SiC film resulting from ALDdeposition using PCDS or HCDS and trimethylaluminum at 400° C.;

FIG. 16 is a graph demonstrating the film thickness and refractive indexversus measurement position;

FIG. 17 is a schematic diagram of a plasma vapor deposition apparatusused in Example 10;

FIG. 18 is a XPS depth profile of the Si(C)N film resulting from ALDdeposition using pentakis(dimethylamino)disilane and N₂ plasma at 275°C.; and

FIG. 19 is a graph of the average ALD deposition rate and inAngstroms/cycle (square) and refractive index (circle) of the Si(C)Nfilms deposited using pentakis(dimethylamino)disilane and N₂ plasmaversus purge time in seconds.

DESCRIPTION OF PREFERRED EMBODIMENTS

Processes for the deposition of silicon-containing films on one or moresubstrates are disclosed. The vapor of a silicon-containing film formingcomposition is introduced into a reactor having a substrate disposedtherein. The silicon-containing film forming compositions comprises apenta-substituted disilane precursor. At least part of thepenta-substituted disilane precursor is deposited onto the substrate toform the silicon-containing film.

The penta-substituted disilane precursor may be pentachlorodisilane(PCDS or Si₂HCl₅), pentafluorodisilane (Si₂HF₅), pentabromodisilane(Si₂HBr₅), or pentaiododisilane (Si₂HI₅).

Pentachlorodisilane is not currently commercially available. However,methods of producing pentachlorodisilane are known in the art. Onepreferred method is disclosed in JP Pat App No 2014-194723 filed Sep.25, 2014, the contents of which are incorporated by reference herein inits entirety. More particularly, PCDS may be isolated by distillationfrom the chlorosilane by-products produced in the synthesis oftrichlorosilane. The corresponding pentahalodisilanes may be synthesizedin the same manner. The pentahalodisilane may be purified by continuousor fractional batch distillation to a purity ranging from approximately95% w/w to approximately 100% w/w, preferably ranging from approximately99% w/w to approximately 100% w/w. One of ordinary skill in the art willrecognize that the distillation column will require a large number oftheoretical plates in order to purify the pentahalodisilane from itshalodisilane analogs.

The concentration of hexahalodisilane in the purified pentahalodisilanemay range from approximately 0% w/w to approximately 5% w/w, preferablyfrom approximately 0% w/w to approximately 1% w/w. The concentration ofO₂ in the purified pentahalodisilane may range from approximately 0 ppmwto approximately 50 ppmw, preferably from approximately 0 ppmw toapproximately 4 ppmw, and more preferably from approximately 0 ppmw toapproximately 1 ppmw. The purified pentahalodisilane should contain nowater, 0 ppmw, or the two will react. The concentration of Cr in thepurified pentahalodisilane may range from approximately 0 ppmw toapproximately 25 ppmw. The concentration of Fe in the purifiedpentahalodisilane may range from approximately 0 ppmw to approximately100 ppmw. The concentration of Na in the purified pentahalodisilane mayrange from approximately 0 ppmw to approximately 50 ppmw. Theconcentration of Ni in the purified pentahalodisilane may range fromapproximately 0 ppmw and approximately 25 ppmw.

Alternatively, the penta-substituted disilane precursor may bepentakis(dimethylamino)disilane [PDMADS-Si₂H(NMe₂)₅]. PDMADS is also notcurrently commercially available. However, methods of synthesizing itare disclosed, for example, in WO2007/112780 to Dussarrat, the contentsof which are incorporated by reference herein in its entirety. Moreparticularly, pentakis(dimethyamino)chlorodisilane is produced byreacting hexachlorodisilane with more than 5 fold moles of dimethylamine(Me₂NH) in an organic solvent at a temperature from −30° C. to 50° C.PDMADS is formed by reduction of thepentakis(dimethylamino)chlorodisilane using lithium aluminum hydride orsodium boron hydride.

PDMADS may be purified by continuous or fractional batch distillation toa purity ranging from approximately 95% w/w to approximately 100% w/w,preferably ranging from approximately 99% w/w to approximately 100% w/w.One of ordinary skill in the art will recognize that the distillationcolumn will require a large number of theoretical plates in order topurify PDMADS from its aminodisilane analogs.

The concentration of hexa(dimethylamino)disilane in the purified PDMADSmay range from approximately 0% w/w to approximately 5% w/w, preferablyfrom approximately 0% w/w to approximately 1% w/w. The concentration ofO₂ in the purified PDMADS may range from approximately 0 ppmw toapproximately 50 ppmw, preferably from approximately 0 ppmw toapproximately 4 ppmw, and more preferably from approximately 0 ppmw toapproximately 1 ppmw. No water (0 ppmw) can be contained within PDMADSor the two will react. The concentration of Cr in the purified PDMADSmay range from approximately 0 ppmw to approximately 25 ppmw. Theconcentration of Fe in the purified PDMADS may range from approximately0 ppmw to approximately 100 ppmw. The concentration of Na in thepurified PDMADS may range from approximately 0 ppmw to approximately 50ppmw. The concentration of Ni in the purified PDMADS may range fromapproximately 0 ppmw and approximately 25 ppmw.

As illustrated in the following Examples, Applicants have surprisinglyfound that using penta-substituted disilane film forming precursors forthe process of silicon-containing film deposition provides a faster ALDgrowth rate and a reasonable ALD temperature window at which useablefilm is deposited with high purity when compared to films deposited byanalogous hexasubstituted disilanes, such as HCDS or Si₂(NHMe)₆.Applicants believe that the substitution of one ligand of ahexasubstituted disilane, wherein all of the ligands are the same, withH produces a more reactive molecule (i.e., Si₂Cl₆→Si₂HCl₅ orSi₂(NMe₂)₆→Si₂H(NMe₂)₅). The increased reactivity of thepenta-substituted disilane film forming precursors may be due to thesmaller atomic size of the hydrogen ligand compared to the larger atomicsize of the chlorine or dimethylamino ligands in case of HCDS andSi₂(NMe₂)₆, respectively. The smaller sized hydrogen ligand may provideless steric hindrance and therefore a higher possibility of physi- orchemi-sorption onto the substrate or onto the previously formed layer,resulting in faster growth behavior. The hydrogen ligand may also makethe penta-substituted disilane film forming precursors more acidic thanHCDS and Si₂(NMe₂)₆, resulting in higher reactivity. Increasedreactivity may also be due to substitution of one ligand of ahexasubstituted disilane with H, slightly polarizing the Si—Si bond dueto the change from a symmetrical molecule to an unsymmetrical molecule.

The disclosed processes for forming silicon-containing layers on asubstrate using a vapor deposition process may be useful in themanufacture of semiconductor, photovoltaic, LCD-TFT, or flat panel typedevices. The disclosed Si-containing film forming compositions may beused to deposit silicon-containing films using any deposition methodsknown to those of skill in the art. Examples of suitable depositionmethods include chemical vapor deposition (CVD) or atomic layerdeposition (ALD). Exemplary CVD methods include thermal CVD, plasmaenhanced CVD (PECVD), pulsed CVD (PCVD), low pressure CVD (LPCVD),sub-atmospheric CVD (SACVD) or atmospheric pressure CVD (APCVD),hot-wire CVD (HWCVD, also known as cat-CVD, in which a hot wire servesas an energy source for the deposition process), radicals incorporateddeposition, super critical fluid deposition, and combinations thereof.Exemplary ALD methods include thermal ALD, plasma enhanced ALD (PEALD),spatial isolation ALD, hot-wire ALD (HWALD), and combinations thereof.The deposition method is preferably ALD, PE-ALD, or spatial isolationALD in order to provide suitable step coverage and film thicknesscontrol.

The disclosed Si-containing film forming compositions may comprise onlythe penta-substituted disilane precursor. Alternatively, theSi-containing film forming composition may further comprise a solvent,such as toluene, xylene, mesitylene, decane, dodecane, or other suitablehydrocarbons. The disclosed precursors may be present in varyingconcentrations in the solvent.

The disclosed Si-containing film forming compositions are introducedinto a reactor in vapor form by conventional means, such as tubingand/or flow meters. The vapor form of the composition may be producedthrough a conventional vaporization step such as direct vaporization,distillation, or by bubbling. The composition may be fed in liquid stateto a vaporizer (direct liquid injection or “DLI”) where it is vaporizedbefore it is introduced into the reactor. Alternatively, the compositionmay be vaporized by passing a carrier gas into a container containingthe composition or by bubbling the carrier gas into the composition. Thecarrier gas may include, but is not limited to, Ar, He, N₂, and mixturesthereof. Bubbling with a carrier gas may also remove any dissolvedoxygen present in the composition. The carrier gas and composition arethen introduced into the reactor as a vapor.

If necessary, the container of disclosed Si-containing film formingcomposition may be heated to a temperature that permits the compositionto have a sufficient vapor pressure. The container may be maintained attemperatures in the range of, for example, approximately 0° C. toapproximately 150° C. Those skilled in the art recognize that thetemperature of the container may be adjusted in a known manner tocontrol the amount of composition vaporized.

For example, the Si-containing film forming compositions may beintroduced into the reactor using the disclosed Si-containing filmforming composition delivery devices. FIGS. 1 and 2 show two embodimentsof the disclosed delivery devices 1.

FIG. 1 is a side view of one embodiment of the Si-containing filmforming composition delivery device 1. In FIG. 1, the disclosedSi-containing film forming compositions 10 are contained within acontainer 20 having two conduits, an inlet conduit 30 and an outletconduit 40. One of ordinary skill in the precursor art will recognizethat the container 20, inlet conduit 30, and outlet conduit 40 aremanufactured to prevent the escape of the gaseous form of theSi-containing film forming composition 10, even at elevated temperatureand pressure.

The delivery device should be leak tight and be equipped with valvesthat do not permit release of the material. Suitable valves includespring-loaded or tied diaphragm valves. The valve may further comprise arestrictive flow orifice (RFO).

The delivery device may be connected to a gas manifold or in anenclosure. The gas manifold should permit the safe evacuation andpurging of the piping that may be exposed to air when the deliverydevice is replaced so that any residual amounts of the material do notreact. The enclosure may be equipped with sensors and fire controlcapability to control the fire in the case of material release. The gasmanifold should also be equipped with isolation valves, vacuumgenerators, and permit the introduction of a purge gas at a minimum.

The delivery device fluidly connects to other components of thesemiconductor processing tool, such as the gas cabinet disclosed above,via valves 35 and 45. Preferably, the delivery device 20, inlet conduit30, valve 35, outlet conduit 40, and valve 45 are made of 316L EP or 304stainless steel. However, one of ordinary skill in the art willrecognize that other non-reactive materials may also be used in theteachings herein and that any corrosive Si-containing film formingcompositions 10 may require the use of more corrosion-resistantmaterials, such as Hastelloy or Inconel.

In FIG. 1, the end 31 of inlet conduit 30 is located above the surfaceof the Si-containing film forming composition 10, whereas the end 41 ofthe outlet conduit 40 is located below the surface of the Si-containingfilm forming composition 10. In this embodiment, the Si-containing filmforming composition 10 is preferably in liquid form. An inert gas,including but not limited to nitrogen, argon, helium, and mixturesthereof, may be introduced into the inlet conduit 30. The inert gaspressurizes the delivery device 20 so that the liquid Si-containing filmforming composition 10 is forced through the outlet conduit 40 and tocomponents in the semiconductor processing tool (not shown). Thesemiconductor processing tool may include a vaporizer which transformsthe liquid Si-containing film forming composition 10 into a vapor, withor without the use of a carrier gas such as helium, argon, nitrogen ormixtures thereof, in order to deliver the vapor to a chamber where asubstrate is located and treatment occurs in the vapor phase.Alternatively, the liquid Si-containing film forming composition 10 maybe delivered directly to the substrate surface as a jet or aerosol.

FIG. 2 is a side view of a second embodiment of the Si-containing filmforming composition delivery device 1. In FIG. 2, the end 31 of inletconduit 30 is located below the surface of the Si-containing filmforming composition 10, whereas the end 41 of the outlet conduit 40 islocated above the surface of the Si-containing film forming composition10. FIG. 2, also includes an optional heating element 25, which mayincrease the temperature of the Si-containing film forming composition10. In this embodiment, the Si-containing film forming composition 10may be in solid or liquid form. An inert gas, including but not limitedto nitrogen, argon, helium, and mixtures thereof, is introduced into theinlet conduit 30. The inert gas bubbles through the Si-containing filmforming composition 10 and carries a mixture of the inert gas andvaporized Si-containing film forming composition 10 to the outletconduit 40 and on to the components in the semiconductor processingtool.

Both FIGS. 1 and 2 include valves 35 and 45. One of ordinary skill inthe art will recognize that valves 35 and 45 may be placed in an open orclosed position to allow flow through conduits 30 and 40, respectively.Either delivery device 1 in FIG. 1 or 2, or a simpler delivery devicehaving a single conduit terminating above the surface of any solid orliquid present, may be used if the Si-containing film formingcomposition 10 is in vapor form or if sufficient vapor pressure ispresent above the solid/liquid phase. In this case, the Si-containingfilm forming composition 10 is delivered in vapor form through theconduit 30 or 40 simply by opening the valve 35 in FIG. 1 or 45 in FIG.2, respectively. The delivery device 1 may be maintained at a suitabletemperature to provide sufficient vapor pressure for the Si-containingfilm forming composition 10 to be delivered in vapor form, for exampleby the use of an optional heating element 25.

While FIGS. 1 and 2 disclose two embodiments of the Si-containing filmforming composition delivery device 1, one of ordinary skill in the artwill recognize that the inlet conduit 30 and outlet conduit 40 may bothbe located above or below the surface of the Si-containing film formingcomposition 10 without departing from the disclosure herein.Furthermore, inlet conduit 30 may be a filling port. Finally, one ofordinary skill in the art will recognize that the disclosedSi-containing film forming composition may be delivered to semiconductorprocessing tools using other delivery devices, such as the ampoulesdisclosed in WO 2006/059187 to Jurcik et al., without departing from theteachings herein.

The vapor of the disclosed Si-containing film forming compositions isdelivered to the reactor of a semiconductor, photovoltaic, LCD-TFT, flatpanel type devices, refractory materials, or aeronautics tool. Thereactor may be any enclosure or chamber of a device in which vapordeposition methods take place such as without limitation, aparallel-plate type reactor, a cold-wall type reactor, a hot-wall typereactor, a single-wafer reactor, a multi-wafer (i.e., batch) reactor, orother types of deposition systems suitable to cause the precursor toreact and form the layers. All of these exemplary reactors are capableof serving as ALD and/or CVD reactors.

Generally, the reactor contains one or more substrates onto which thefilms will be deposited. A substrate is generally defined as thematerial on which a process is conducted. The substrates may be anysuitable substrate used in semiconductor, photovoltaic, flat panel, orLCD-TFT device manufacturing. Examples of suitable substrates includewafers, such as silicon, silica, glass, or GaAs wafers. The wafer mayhave one or more layers of differing materials deposited on it from aprevious manufacturing step. For example, the wafers may include siliconnitride layers, silicon oxy nitride layers, carbon doped silicon oxide(SiCOH) layers, tor combinations thereof. Additionally, the wafers mayinclude copper layers, tungsten layers, or noble metal layers (e.g.platinum, palladium, rhodium, or gold). Plastic layers, such aspoly(3,4-ethylenedioxythiophene)poly (styrenesulfonate) [PEDOT:PSS] mayalso be used. The layers may be planar or patterned. The disclosedprocesses may deposit the silicon-containing layer directly on the waferor directly on one or more than one layer (when patterned layers formthe substrate) of the layers on top of the wafer. Throughout thespecification and claims, the wafer and any associated layers thereonare referred to as substrates. For example, a Cu film may be depositedonto a SiC layer. In subsequent processing, a SiC layer may be depositedon the Cu layer, forming a SiC/Cu/SiC stack used in a damascenestructure in the back end of the line (BEOL).

The temperature and the pressure within the reactor are held atconditions suitable for vapor deposition. In other words, afterintroduction of the vaporized composition into the chamber, conditionswithin the chamber are such that at least part of the penta-substituteddisilane precursor is deposited onto the substrate to form thesilicon-containing film. For instance, the pressure in the reactor maybe held between about 1 Pa and about 10⁵ Pa, more preferably betweenabout 25 Pa and about 10³ Pa, as required per the deposition parameters.Likewise, the temperature in the reactor may be held between about 100°C. and about 800° C. One of ordinary skill in the art will recognizethat “at least part of the penta-substituted disilane precursor isdeposited” means that some or all of the precursor reacts with oradheres to the substrate.

The temperature of the reactor may be controlled by either controllingthe temperature of the substrate holder or controlling the temperatureof the reactor wall. Devices used to heat the substrate are known in theart. The reactor wall is heated to a sufficient temperature to obtainthe desired film at a sufficient growth rate and with desired physicalstate and composition. A non-limiting exemplary temperature range towhich the reactor wall may be heated includes from approximately roomtemperature (20° C.) to approximately 500° C. When a plasma depositionprocess is utilized, the deposition temperature may range fromapproximately room temperature (20° C.) to approximately 400° C.Alternatively, when ozone is used as a reactant, the depositiontemperature may range from approximately 100° C. to approximately 400°C. In another alternative, when a thermal process is performed, thedeposition temperature may range from approximately 200° C. toapproximately 500° C.

In addition to the disclosed Si-containing film forming compositions, areactant may also be introduced into the reactor. The reactant may be anoxidizing gas such as one of O₂, O₃, H₂O, H₂O₂, NO, N₂O, NO₂, oxygencontaining radicals such as O. or OH., NO, NO₂,carboxylic acids, formicacid, acetic acid, propionic acid, and mixtures thereof. Typically, theoxidizing gas is selected from the group consisting of O₂, O₃, H₂O,H₂O₂, oxygen containing radicals thereof such as O. or OH., and mixturesthereof. More typically, the oxidizing gas is O₂, O₃, O₂ plasma, orcombinations thereof.

The reactant may be treated by a plasma, in order to decompose thereactant into its oxygen containing radical form. For instance, theplasma may be generated with a power ranging from about 50 W to about500 W, preferably from about 100 W to about 200 W. The plasma may begenerated or present within the reactor itself. Alternatively, theplasma may generally be at a location removed from the reactor, forinstance, in a remotely located plasma system. One of skill in the artwill recognize methods and apparatus suitable for such plasma treatment.

For example, the reactant may be introduced into a direct plasmareactor, which generates plasma in the reaction chamber, to produce theplasma-treated reactant in the reaction chamber. Exemplary direct plasmareactors include the Titan™ PECVD System produced by Trion Technologies.The reactant may be introduced and held in the reaction chamber prior toplasma processing. Alternatively, the plasma processing may occursimultaneously with the introduction of the reactant. In-situ plasma istypically a 13.56 MHz RF inductively coupled plasma that is generatedbetween the showerhead and the substrate holder. The substrate or theshowerhead may be the powered electrode depending on whether positiveion impact occurs. Typical applied powers in in-situ plasma generatorsare from approximately 30 W to approximately 1000 W. Preferably, powersfrom approximately 30 W to approximately 600 W are used in the disclosedmethods. More preferably, the powers range from approximately 100 W toapproximately 500 W. The disassociation of the reactant using in-situplasma is typically less than achieved using a remote plasma source forthe same power input and is therefore not as efficient in reactantdisassociation as a remote plasma system, which may be beneficial forthe deposition of Si-containing films on substrates easily damaged byplasma.

Alternatively, the plasma-treated reactant may be produced outside ofthe reaction chamber. The MKS Instruments' ASTRONi® reactive gasgenerator may be used to treat the reactant prior to passage into thereaction chamber. Operated at 2.45 GHz, 7 kW plasma power, and apressure ranging from approximately 3 Torr to approximately 10 Torr, thereactant O₂ may be decomposed into two O. radicals. Preferably, theremote plasma may be generated with a power ranging from about 1 kW toabout 10 kW, more preferably from about 2.5 kW to about 7.5 kW.

The resulting silicon oxide films may be used as capacitors andinsulating layers.

Silicon oxides may be deposited using pentakis(dimethylamino)disilaneand an oxidizing gas in an ALD or CVD process. The process may be athermal ALD process at a temperature ranging from approximately 100° C.to approximately 400° C. when using an ozone reactant. Alternatively,the process may be a plasma enhanced ALD process at a temperatureranging from approximately room temperature (approximately 23° C.) to400° C. ALD depositions of silicon oxide films using thepentakis(dimethylamino)disilane precursor are expected to producedeposition rates on the order of approximately 1 angstrom/cycle. Mostalkyl amino monosilanes exhibit a lower deposition rate, typicallyapproximately 0.5 angstroms/cycle.

As illustrated in the examples, silicon oxide films may also bedeposited at high temperatures using pentachlorodisilane and anoxidizing gas in an ALD or CVD process. The temperature may range fromapproximately 450° C. to approximately 800° C., preferably fromapproximately 450° C. to approximately 600° C., and more preferably fromapproximately 500° C. to approximately 600° C. High temperature siliconoxide film deposition is important to produce films having high density,low wet etch rates, and low contaminant levels, for example, with metalimpurities ranging from 10⁹ to 10¹⁷ atoms/cm³. In fact, as shown inExamples 2-5, ALD depositions using pentachlorodisilane and anozone/oxygen mixture exhibited self-limited growth at a temperaturerange of approximately 550° C. to approximately 650° C. The resultingfilm had little to no nitrogen or chlorine contamination. The resultingsilicon oxide film preferably contains between approximately 0 atomic %and approximately 1 atomic % nitrogen. The resulting silicon oxide filmalso contains between approximately 0 atomic % and approximately 1atomic % chlorine.

Alternatively, the reactant may be a reducing gas such as one of H₂,H₂CO, NH₃, SiH_(4,) Si₂H₆, Si₃H₈, (CH₃)₂SiH₂, (C₂H₅)₂SiH₂, (CH₃)SiH₃,(C₂H₅)SiH₃, phenyl silane, N₂H₄, N(SiH₃)₃, N(CH₃)H₂, N(C₂H₅)H₂,N(CH₃)₂H, N(C₂H₅)₂H, N(CH₃)₃, N(C₂H₅)₃, (SiMe₃)₂NH, (CH₃)HNNH₂,(CH₃)₂NNH₂, phenyl hydrazine, N-containing molecules, B₂H₆,9-borabicyclo[3,3,1]nonane, dihydrobenzofuran, pyrazoline,trimethylaluminium, dimethylzinc, diethylzinc, radical species thereof,and mixtures thereof. Preferably, the reducing as is H₂, NH₃, SiH_(4,)Si₂H₆, Si₃H₈, SiH₂Me₂, SiH₂Et₂, N(SiH₃)₃, hydrogen radicals thereof, ormixtures thereof.

In another alternative, the reactant may be a nitrogen-containingreactant such as one of NH₃, N₂H₄, N(SiH₃)₃, N(CH₃)H₂, N(C₂H₅)H₂,N(CH₃)₂H, N(C₂H₅)₂H, N(CH₃)₃, N(C₂H₅)₃, (SiMe₃)₂NH, (CH₃)HNNH₂,(CH₃)₂NNH₂, nitrogen-containing radical species thereof, and mixturesthereof.

As disclosed above with respect to the oxidizing gas reactant, thereducing gas or nitrogen containing reactant may also be treated by aplasma in order to decompose the reactant into its radical form. N₂ mayalso be utilized as a reducing gas when treated with plasma and a blendof N₂ and H₂ may be used in a remote plasma process. The plasma may begenerated in situ or remotely, as detailed described in further detailedabove.

For example, as illustrated in Examples 7 and 8, silicon nitride filmsmay be deposited at medium range temperatures using pentachlorodisilaneand a N-containing gas in an ALD or CVD process. The temperature mayrange from approximately 350° C. to approximately 650° C., preferablyfrom approximately 450° C. to approximately 650° C., and more preferablyfrom approximately 550° C. to approximately 600° C. This medium rangetemperature is important to the silicon nitride deposition processbecause the underlying substrate may not be able to withstand higherprocess temperatures without sustaining damage. In fact, as shown inExample 8, ALD depositions using pentachlorodisilane and an ammoniareactant produced silicon nitride films having a refractive indexranging from approximately 1.7 to approximately 2.2. The refractiveindex of pure silicon nitride is 2.0. The incorporation of oxygen or aporous film will lower the refractive index and an excess of siliconwill increase the refractive index. As shown in Example 8 and FIG. 14,the resulting film had little to no carbon and traces of oxygen andchlorine contamination. The silicon nitride film may contain betweenapproximately 0 atomic % and approximately 5 atomic % carbon, preferablybetween approximately 0 atomic % and approximately 2.5 atomic % carbon;and more preferably between approximately 0 atomic % and approximately 1atomic % carbon. The silicon nitride film may also contain betweenapproximately 0.1 atomic % and approximately 1 atomic % oxygen. Finally,the silicon nitride film may contain between approximately 0.1 atomic %and approximately 1 atomic % chlorine.

The silicon nitride films produced using the disclosed penta-substituteddisilane and nitrogen-containing reactant may be used as a spacer for afin double patterning process, as a spacer for dual Epi sidewall, as acontact etch stop layer, or as a capping layer for self aligned contactsin FinFET. When used as a spacer for the fin double patterning process,the silicon nitride growth rate does not exhibit pattern loading effect(the growth rate being lower on a dense feature as compared to flatareas of the substrate). When used as a spacer for a dual Epi sidewallor as a contact etch stop layer, the silicon nitride film has a lowdielectric constant (between approximately 3 to approximately 6,preferably between approximately 4.5 and approximately 5.5) and a low HFwet etch rate (between 0 Ang/sec and 10 Ang/sec for 1% HF at roomtemperature).

The silicon nitride films produced using the disclosed penta-substituteddisilane and nitrogen-containing reactant may also be used in DRAMmanufacturing. More particularly, the silicon nitride layer may serve asa DRAM spacer, a Buried Word Line (BWL) nitride cap, a bit line spacer,or a low-k Etch Stop Layer (ESL) for capacitors.

The silicon nitride layers produced using the disclosedpenta-substituted disilane and nitrogen-containing reactant may also beused as a nitride trap layer in 3D NAND manufacturing. The nitride traplayer should have no seam and a low dielectric constant (betweenapproximately 3 to approximately 6, preferably between approximately 4.5and approximately 5.5).

The silicon nitride layers produced using the disclosedpenta-substituted disilane and nitrogen-containing reactant may also beused for encapsulation in MRAM manufacturing. The films needs to bedeposited at low temperature (between approximately 200° C. andapproximately 500° C., preferably between approximately 275° C. andapproximately 350° C.) and should be halide free (containing betweenapproximately 0.1 atomic % and approximately 1 atomic % halide). PEALDis particularly suitable for these applications.

The silicon nitride layers produced using the disclosedpenta-substituted disilane and nitrogen-containing reactant may also beused as air gap lines in advanced interconnect manufacturing. The airgap lines need to be deposited at low temperatures (betweenapproximately 200° C. and approximately 500° C., preferably betweenapproximately 275° C. and approximately 350° C.), have a low dielectricconstant (between approximately 3 to approximately 6, preferably betweenapproximately 4.5 and approximately 5.5), have a low wet etch rate(between 0 Ang/sec and 10 Ang/sec for 1% HF at room temperature), and behalide free (containing between approximately 0.1 atomic % andapproximately 1 atomic % halide).

As shown in Example 10, carbon doped silicon nitrides may also bedeposited using the penta-substituted disilanes, such aspentakis(dimethylamino)disilane, and a nitrogen containing reactant in alow temperature plasma enhanced ALD process. Preferably, the nitrogencontaining reactant is NH₃, N₂, or a combination of N₂ and H₂. The H₂concentration in the combination of N₂ and H₂ may range fromapproximately 0% vol/vol to approximately 70% vol/vol. For example, theN₂:H₂ ratio may be 1:1. The process temperature may range fromapproximately 100° C. to approximately 350° C. The carbon concentrationin the carbon doped silicon nitride film may range from approximately 1atomic % to approximately 15 atomic %.

In another alternative, the reactant may be an amine, alkylaminosilane,or a disilazane to produce a carbon doped silicon nitride film.Exemplary amines include ammonia. Exemplary alkylaminosilanes includebis(diethylamino)silane or tris(dimethylamino)silane. Exemplarydisilazanes include hexamethyldisilazane. The carbon doped siliconnitride film preferably has a carbon concentration ranging fromapproximately 2 atomic % to approximately 15 atomic %, a nitrogenconcentration ranging from approximately 10 atomic % to approximately 50atomic %, and an oxygen concentration ranging from approximately 0atomic % to approximately 5 atomic %.

In another alternative, the reactant may be an alkyl substituted metalor metalloid. The alkyl substituted metal or metalloid may have theformula AlR₃, with each R independently being H, Me, Et, nPr, iPr, nBu,iBu, or NR2, provided that when R₃═H₃ that the molecule may be adductedwith an amine or borohydride. For example, the alkyl substituted metalor metalloid being triethyl aluminum, trimethyl aluminum, or AlH₃.NH₃.Alternatively, the alkyl substituted metal or metalloid may have theformula BR₃, with each R independently being an alkyl or an allyl group.For example, the alkyl substituted metal or metalloid may be triethylboron or trimethyl boron. Alternatively, the alkyl substituted metal ormetalloid may have the formula AlClR₂, with each R independently beingH, Me, Et, nPr, iPr, nBu, or iBu, or NR₂. In another alternative, thealkyl substituted metal or metalloid may have the formula BXR₂, with Xbeing Cl, Br, or I and each R independently being an alkyl or an allylgroup. In yet another alternative, the alkyl substituted metal ormetalloid having the formula ZnR₂, with each R independently being Me,Et, nPr, iPr, nBu, or iBu. In another alternative, the alkyl substitutedmetal or metalloid having the formula GaR₃, with each R independentlybeing Me, Et, nPr, iPr, nBu, iBu, or NR₂. For example, the alkylsubstituted metal or metalloid being trimethyl gallium. In yet anotheralternative, the alkyl substituted metal or metalloid having the formulaInR₃, with each R independently being Me, Et, nPr, iPr, nBu, iBu, orNR₂.

As shown in Example 9, the penta-substituted disilane and the alkylsubstituted metal or metalloid may be used to deposit silicon carbidefilms using an ALD process. However, in addition to the disclosedpenta-substituted disilanes, Applicants believe that any silicon halideprecursors may be useful in this process, provided the precursorcontains at least one halide, because the halide reacts with the metalor metalloid forming a volatile halide.

Additional silicon halides that may be suitable for use in the ALDdeposition of silicon carbide films include silicon halides having theformula SiX₄, each X independently being Cl, Br, I, H, or R, with Rbeing an aliphatic group. Exemplary silicon halides include SiCl₃H,SiH₂Cl₂, SiH₃Cl, SiI₂H₂, SiHMeI₂, or SiMe₂I₂. In another alternative,the silicon halide may have the formula Si₂X₆, with each X independentlybeing Cl, Br, I, or H. Exemplary silicon halides includepentachlorodisilane, hexachlorodisilane, hexaiododisilane,monochlorodisilane, monobromodisilane, monoiododisilane,dichlorodisilane [H₂ClSi—SiCIH₂], dibromodisilane [H₂BrSi—SiBrH₂],diiododisilane [H₂ISi—SiIH₂], dichlorodisilane [H₃Si—SiHCl₂],dibromodisilane [H₃Si—SiHBr₂], or diiododisilane [H₃Si—SiHI₂]. Inanother alternative, the silicon halide may have the formulaX₃Si—CH₂—SiX₃, with each X independently being Cl, Br, I, or H, such asbis(trichlorosilyl)methane [Cl₃Si—CH₂—SiCl₃] orbis(dichlorosilyl)methane [(SiClH₂)₂CH₂]. In another alternative, thesilicon halide may have the formula X₃Si—CH₂—CH₂—SiX₃, with each Xindependently being Cl, Br, I, or H, such as Cl₃Si—CH₂—CH₂—SiCl₃. Inanother alternative, the silicon halide may have the formulaX₃Si—CH₂—SiX₂—CH₂—SiX₃, with each X independently being CI or H,provided at least one terminal X is Cl. Exemplary silicon halidesinclude Cl₃Si—CH₂—SiCl₂—CH₂—SiCl₃ or H₃Si—CH₂—SiH₂—CH₂—SiClH₂. In yetanother alternative, the silicon halide may have the cyclic formula(—SiX₂—CH₂—)₃, with each X independently being Cl, Br, or I, such as(—SiCl₂—CH₂—)₃. In yet another alternative, the silicon halide may havethe cyclic formula (—SiHX—CH₂—)₃, with each X independently being Cl,Br, or I, such as (—SiHCl—CH₂—)₃. The silicon halide may also beoctachlorotrisilane (OCTS or Si₃Cl₈), decachlorotetrasilane (Si₄Cl₁₀) ordodecachloropentasilane (DCPS or Si₅Cl₁₂). These silicon halides areeither commercially available or may be synthesized by methods known inthe art.

The vapor deposition conditions within the chamber allow the disclosedprecursor and the reactant to react and form a silicon-containing filmon the substrate. In some embodiments, Applicants believe thatplasma-treating the reactant may provide the reactant with the energyneeded to react with the disclosed precursor.

Depending on what type of film is desired to be deposited, an additionalprecursor compound may be introduced into the reactor. The precursor maybe used to provide additional elements to the silicon-containing film.The additional elements may include lanthanides (Ytterbium, Erbium,Dysprosium, Gadolinium, Praseodymium, Cerium, Lanthanum, Yttrium),germanium, silicon, titanium, manganese, ruthenium, bismuth, lead,magnesium, aluminum, or mixtures of these. When an additional precursorcompound is utilized, the resultant film deposited on the substratecontains silicon in combination with at least one additional element.

The Si-containing film forming compositions and reactants may beintroduced into the reactor either simultaneously (chemical vapordeposition), sequentially (atomic layer deposition) or differentcombinations thereof. The reactor may be purged with an inert gasbetween the introduction of the composition and the introduction of thereactant. Alternatively, the reactant and the composition may be mixedtogether to form a reactant/composition mixture, and then introduced tothe reactor in mixture form. Another example is to introduce thereactant continuously and to introduce the Si-containing film formingcomposition by pulse (pulsed chemical vapor deposition).

The vaporized Si-containing film forming composition and the reactantmay be pulsed sequentially or simultaneously (e.g. pulsed CVD) into thereactor. Each pulse of the composition may last for a time periodranging from about 0.01 seconds to about 10 seconds, alternatively fromabout 0.3 seconds to about 3 seconds, alternatively from about 0.5seconds to about 2 seconds. In another embodiment, the reactant may alsobe pulsed into the reactor. In such embodiments, the pulse of each gasmay last for a time period ranging from about 0.01 seconds to about 10seconds, alternatively from about 0.3 seconds to about 3 seconds,alternatively from about 0.5 seconds to about 2 seconds. In anotheralternative, the vaporized composition and one or more reactants may besimultaneously sprayed from a shower head under which a susceptorholding several wafers is spun (spatial ALD).

Depending on the particular process parameters, deposition may takeplace for a varying length of time. Generally, deposition may be allowedto continue as long as desired or necessary to produce a film with thenecessary properties. Typical film thicknesses may vary from severalangstroms to several hundreds of microns, depending on the specificdeposition process. The deposition process may also be performed as manytimes as necessary to obtain the desired film.

In one non-limiting exemplary CVD type process, the vapor phase of thedisclosed Si-containing film forming composition and a reactant aresimultaneously introduced into the reactor. The two react to form theresulting silicon-containing film. When the reactant in this exemplaryCVD process is treated with a plasma, the exemplary CVD process becomesan exemplary PECVD process. The reactant may be treated with plasmaprior or subsequent to introduction into the chamber.

In one non-limiting exemplary ALD type process, the vapor phase of thedisclosed Si-containing film forming composition is introduced into thereactor, where it is contacted with a suitable substrate. Excesscomposition may then be removed from the reactor by purging and/orevacuating the reactor. A desired gas (for example, H₂) is introducedinto the reactor where it reacts with the chemi- or physi-sorbedprecursor in a self-limiting manner. Any excess reducing gas is removedfrom the reactor by purging and/or evacuating the reactor. If thedesired film is a Si film, this two-step process may provide the desiredfilm thickness or may be repeated until a film having the necessarythickness has been obtained.

Alternatively, if the desired film contains silicon and a secondelement, the two-step process above may be followed by introduction ofthe vapor of an additional precursor compound into the reactor. Theadditional precursor compound will be selected based on the nature ofthe silicon-containing film being deposited. After introduction into thereactor, the additional precursor compound is contacted with thesubstrate. Any excess precursor compound is removed from the reactor bypurging and/or evacuating the reactor. Once again, a desired gas may beintroduced into the reactor to react with the physi- or chemi-sorbedprecursor compound. Excess gas is removed from the reactor by purgingand/or evacuating the reactor. If a desired film thickness has beenachieved, the process may be terminated. However, if a thicker film isdesired, the entire four-step process may be repeated. By alternatingthe provision of the Si-containing film forming composition, additionalprecursor compound, and reactant, a film of desired composition andthickness can be deposited.

When the reactant in this exemplary ALD process is treated with aplasma, the exemplary ALD process becomes an exemplary PEALD process.The reactant may be treated with plasma prior or subsequent tointroduction into the chamber.

The silicon-containing films resulting from the processes discussedabove may include silicon oxide, silicon nitride, silicon carbide, andcarbon doped silicon nitride films. One of ordinary skill in the artwill recognize that by judicial selection of the appropriateSi-containing film forming composition, optional precursor compounds,and reactant species, the desired film composition may be obtained.

Upon obtaining a desired film thickness, the film may be subject tofurther processing, such as thermal annealing, furnace-annealing, rapidthermal annealing, UV or e-beam curing, and/or plasma gas exposure.Those skilled in the art recognize the systems and methods utilized toperform these additional processing steps. For example, thesilicon-containing film may be exposed to a temperature ranging fromapproximately 200° C. and approximately 1000° C. for a time ranging fromapproximately 0.1 second to approximately 7200 seconds under an inertatmosphere, a H-containing atmosphere, a N-containing atmosphere, anO-containing atmosphere, or combinations thereof. Most preferably, thetemperature is 400° C. for 3600 seconds under a H-containing atmosphereor an 0-containing atmosphere. Alternatively, annealing may be performedunder a Si-containing atmosphere, provided the process is performed at atemperature below the decomposition temperature of thesilicon-containing compound. Exemplary silicon-containing molecules thatmay be used to form the silicon-containing atmosphere include SiH₄,Si₂H₆, MeSiH₃, Me₂SiH₂, aminosilanes, isocyanato silanes (R—Si—NCO),such as Tetra(isocyanato)silane (TICS). The resulting film may containfewer impurities and therefore may have an improved density resulting inimproved leakage current. The annealing step may be performed in thesame reaction chamber in which the deposition process is performed.Alternatively, the substrate may be removed from the reaction chamber,with the annealing/flash annealing process being performed in a separateapparatus. Any of the above post-treatment methods, but especiallythermal annealing, has been found effective to densify the films andreduce wet etch rates. This in turn tends to improve the resistivity ofthe film.

EXAMPLES

The following examples illustrate experiments performed in conjunctionwith the disclosure herein. The examples are not intended to be allinclusive and are not intended to limit the scope of disclosuredescribed herein.

Example 1 Pyrolysis test of Pentachlorodisilane [PCDS or Si₂HCl₅]

FIG. 3 is a schematic diagram of deposition apparatus used for thefollowing testing. The apparatus includes a hotwall tube reactor 100containing substrate coupons 105. A pump 110 removes the contents fromthe hotwall tube reactor 100.

The vapor of the disclosed Si-containing film forming composition isintroduced to the hotwall tube reactor 100 from delivery device 200 vialine 201. An inert gas 205, such as N₂, is delivered to the deliverydevice 200 via line 206. The inert gas 205 may also be delivered to thereactor 100 via line 207.

An oxidizing gas may be introduced to the hotwall tube reactor 100 fromdelivery device 300 via line 301. When the oxidizing gas is ozone, line301 may include an ozone generator 303 and ozone monitor 304. Oxidizinggas may also be delivered to the exhaust 311.

A nitrogen containing gas may be introduced to the hotwall tube reactor100 from delivery device 400 via line 401.

One of ordinary skill in the art will recognize that lines 201, 206,207, 301, and 401 may include numerous pressure gauges, check valves,valves, and pressure regulators and that additional lines for pressureregulation or by-pass flow have not been included in order to simplifythe drawing.

To examine the thermal decomposition behavior of PCDS, pyrolysis testingwas performed in the deposition apparatus of FIG. 3 at 4 differenttemperatures (400, 500, 600 and 700° C.) for 30 min on a SiO₂ substrateor coupon. The hot wall tube reactor was kept at 1 Torr, with 4 sccm ofa continuous flow of PCDS into the reaction chamber using 50 sccm of N₂as a carrier gas. Pyrolysis mimics chemical vapor deposition without areactant and illustrates the temperature at which the precursor selfdecomposes.

FIGS. 4(a), (b), (c), and (d) are X-ray Photoelectron Spectroscopy (XPS)depth profiles of the resulting Si films. As can be seen in FIGS. 4(a)and (b), no thermal decomposition of PCDS occurred because no siliconlayers were formed, with the testing revealing the original SiO₂substrate. FIG. 4(c) reveals partial decomposition of the PCDS resultingin a Si-rich SiO₂ layer at 600° C. As can be seen in FIG. 4(d), analmost 100% Si layer having little to no O, Cl or C inclusion was formedon the SiO₂ substrate from decomposition of PCDS alone at 600˜700° C.

Comparative Example 1 Pyrolysis test of Hexachlorodisilane [HCDS orSi₂Cl₆]

Comparative pyrolysis testing of hexachlorodisilane (HCDS or Si₂Cl₆) wasperformed at 4 different temperatures (400, 500, 600 and 700° C.) for 30min on a SiO₂ substrate in the deposition apparatus of FIG. 3. The hotwall tube reactor was kept at 1 Torr, with 4 sccm of a continuous flowof HCDS into the reaction chamber using 50 sccm of N₂ as a carrier gas.

FIGS. 5(a), (b), (c), and (d) show X-ray Photoelectron Spectroscopy(XPS) depth profiles of the resulting Si-containing films. As can beseen, no pure Si layers were formed by HCDS decomposition at anytemperature.

Example 2 SiO₂ ALD using PCDS or HCDS and O₃/O₂

SiO₂ ALD was performed using PCDS with O₃ as an oxidizing agent at thetemperature range of 500˜700° C. on Si substrates. The reaction furnaceof FIG. 3 was controlled at 1 Torr and 50 sccm of N₂ was continuouslyflowed. The ALD process included the following steps: 1) supply a pulseof 4 sccm of PCDS to the reaction chamber for 10 seconds, 2) purge theexcess precursors by 50 sccm of N₂ for 90 seconds, 3) supply ˜7.2% ofO₃/O₂ (O₂: 100 sccm) to the chamber for 10 seconds, 4) purge excessO₃/O₂ by 50 sccm of N₂ for 30 seconds. The sequence from 1) to 4) wasrepeated for 200 cycles, until the deposited layer achieved suitablethickness for film characterization (i.e., over 100 Å). The method wasrepeated with HCDS replacing PCDS with the same ALD process conditionsas PCDS. The average deposition rates from 4 separate coupon substratelocations using PCDS (circle) and 4 separate coupon locations using HCDS(triangle) are shown in FIG. 6.

The deposition rate of PCDS increased from 500° C. to 600° C., andexhibited a plateau between 600° C. and 650° C., then increased again upto 700° C. From this temperature dependency of deposition rate of PCDSin ALD process, an ALD window may be observed between 600° C. and 650°C. However in the same Figure, the deposition rate of HCDS continuouslyincreased in the temperature range of 500° C. to 700° C. As a result, noconsiderable ALD window was observed for HCDS. Applicants believe thatthe SiO₂ ALD window (i.e., 600-650° C.) obtained from PCDS provides thehighest temperature ALD window using a chlorosilane based Si precursors,like monochlorosilane or hexachlorodisilane. One of ordinary skill inthe art will recognize that temperature and pressure may be manipulatedto change this ALD deposition window.

Example 3 SiO₂ ALD Saturation Behavior of PCDS and O₃

Based on the results from Example 2, the PCDS pulse time dependency ofSiO₂ALD growth behaviour is examined at two temperatures, 550° C. and600° C., and the result is provided in FIG. 7. The same processconditions used for the temperature dependency test in Example 2 wereapplied to this evaluation, except the pulse time of PCDS was varied atboth 550° C. (diamond) and 600° C. (square). At both temperatures,stable average deposition rates are observed with pulse times of PCDSbetween 10-15 seconds from 3-5 locations on the coupon: 0.91˜0.94Å/cycle at 600° C. and 0.50˜0.52 Å/cycle at 550° C. The consistentdeposition rates are considered a characteristic of ALD saturation.

Example 4 SiO₂ ALD Film Composition by XPS

XPS analysis was performed for SiO₂ ALD films deposited in Example 2from PCDS on Si substrates at 550, 600, 650, and 700° C. to examine thefilm composition. FIGS. 8a-d shows the result of XPS depth profile of5-elements, Si, Cl, C, N and O. No Cl, C and N was detected in thefilms. The XPS sputter energy was set higher for the films deposited at650° and 700° C. than for those deposited at 550° C. and 600° C. As aresult, the analysis results for the etch times of the films depositedat 650° and 700° C. penetrates deeper into the films than equivalentetch times of the films deposited at 550° C. and 600° C.

Example 5 Step Coverage of SiO₂ ALD Film Using PCDS

Step coverage of SiO₂ films deposited by ALD was examined on patternwafers with holes having an aspect ratio (AR)=40 with a 8 micrometerdepth at 600° C. The reaction furnace of FIG. 3 was controlled at 1 Torrand 50 sccm of N₂ was continuously flowed. The ALD process included thefollowing steps: 1) supply a pulse of 4 sccm of PCDS to the reactionchamber for 10 seconds, 2) purge the excess precursors by 50 sccm of N₂for 90 seconds, 3) supply ˜7.2% of O₃/O₂ (O2: 100 sccm) to the chamberfor 10 seconds, 4) purge excess O₃/O₂ by 50 sccm of N₂ for 10 seconds.The sequence from 1) to 4) was repeated for 350 cycles. FIGS. 9 and9(a)-(c) are scanning electron microscope pictures showing the resultingstep coverage in the entire hole (FIG. 9) and three different positionswithin FIG. 9: (FIG. 9(a)) top step coverage=93%, (FIG. 9(b)) middle(around 2 micrometer depth from top) step coverage=77% and (FIG. 9(c))bottom step coverage=73%.

Example 6 Catalytic Low Temperature SiO₂ ALD

SiO₂ films were deposited using ALD with PCDS, H₂O as an oxidizingagent, and triethylamine (TEA) as a catalyst. The reaction furnace ofFIG. 3 was controlled at 5 Torr, at the temperature range of 50˜100° C.,and 200 sccm of Ar was continuously flowed. The deposition processincluded the following steps: 1) introducing a pulse of 1 sccm of PCDSand 50 sccm of TEA to the reaction furnace for 10 seconds, 2) purgingexcess PCDS and TEA from the reaction furnace by 1 slm of Ar for 10seconds, 3) introducing 15 sccm of H₂O and 50 sccm of TEA and 1 slm ofAr to the furnace for 20 seconds, 4) purging excess H₂O and TEA by 1 slmof Ar for 20 seconds. The sequence from 1) to 4) was repeated for 300cycles.

FIG. 10 is a graph demonstrating the process temperature dependence ofdeposition rate (hollow diamond) and refractive index (solid square).Deposition rates of ˜1.4 Å/cycle and refractive index of ˜1.39 wasobtained at 70° C., indicating a low density film that may be suitablefor sacrificial use. FIG. 11 is a graph demonstrating the XPS depthprofile of the deposited SiO₂ film at 70° C., which demonstrates thatthe resulting film contains no impurities.

Example 7 Low Temperature CVD of SiN

SiN films were deposited via CVD using PCDS (circle) or HCDS (square) asa Si source and ammonia (NH₃) as a nitridation source. The reactionfurnace of FIG. 3 was controlled at 1 Torr, temperature varied from 450°C. to 600° C., and 100 sccm of Ar was continuously flowed. A mixed gasflow of 1 sccm of Si source and 25 sccm of NH₃ was supplied to thereaction furnace for 60˜120 minutes, until the deposited layer achievedsuitable thickness. FIG. 12 is a graph illustrating the deposition rate(hollow) and refractive index (solid) obtained with PCDS+NH₃ than thatwith HCDS+NH₃.

Example 8 Medium Temperature ALD of SiN

SiN films were deposited via ALD using PCDS (circle), HCDS (square), orOCTS (octachlorotrisilane)(triangle) as a Si source and ammonia (NH₃) asa nitridation source. The pressure in the reaction furnace of FIG. 3 iscontrolled at 5 Torr, the temperature varied from 350° C. to 600° C.,and 100 sccm of Ar was continuously flowing. The deposition processincludes the following steps: 1) introducing a pulse of 1 sccm of Sisource to the reaction furnace for 10 seconds, 2) purging excess Sisource from the reaction furnace by 1 slm of Ar for 10 seconds, 3)introducing 50 sccm of NH₃ to the reaction furnace, and 4) purgingexcess NH₃ from the reaction furnace by 1 slm of Ar for 20 seconds. Thesequence from 1) to 4) were repeated for 200˜400 cycles, until thedeposited layer achieved suitable thickness of over 100 Å.

FIG. 13 is a graph demonstrating the temperature dependence of the PCDS(circle), HCDS (square), and OCTS (triangle) deposition rates (hollow)and refractive indices (solid) from the process.

PCDS exhibited higher deposition rates and refractive indices ascompared to HCDS or OCTS, except the refractive index value of HCDS ishigher at 400° C. and 550° C. The deposition rate of PCDS and HCDSexhibit a plateau between 550° C. and 600° C., indicating self-limitingALD behavior, but no plateau was observed from OCTS.

FIG. 14 is a graph demonstrating the XPS depth profile of the SiN filmdeposited at 600° C. with PCDS and NH₃, including the 54% of Si, 45% ofN, and trace amount of 0, C, and Cl impurities.

As shown in FIG. 13, silicon nitride films with refractive indices thatmay be acceptable for use in the fabrication of semiconductor devicesare deposited at substrate temperatures ranging from 450° C. to 600° C.using PCDS and ranging from 500° C. to 600° C. using HCDS. Therefractive index of silicon nitride films deposited from OCTS onlybecome commercially viable at 600° C. Furthermore, the deposition rateof silicon nitride films from PCDS is substantially higher than fromHCDS within this temperature range (i.e., 40%-100% higher). Using PCDStherefore allows formation of a high quality silicon nitride film at alower temperature and with a surprisingly high deposition rate. Thetemperature range extension producing refractive indices near that ofpure silicon nitride for PCDS as compared to HCDS is also surprising andbeneficial for producing semiconductor devices. A desired siliconnitride film may be obtained at substrate temperatures 50° C. lower thanwas possible using the industry standard material HCDS. The lowertemperature permits a lower thermal budget in processing which allowsfor more flexibility and options for subsequent processing steps.

Example 9 Low Temperature ALD of SiC

SiC films were deposited via ALD using PCDS (square) or HCDS (triangle)as a Si source and trimethylalumimum (TMA) as a carbon source. Thepressure in the reaction furnace of FIG. 3 was controlled at 8 Torr, thetemperature varied from 350° C. to 400° C., and 10 sccm of N₂ wascontinuously flowing. The deposition process includes the followingsteps: 1) introducing a pulse of 0.8 sccm of Si source to the reactionfurnace for 15 seconds, 2) purging excess Si source from the reactionfurnace by 25 sccm of N₂ for 30 seconds, 3) introducing 1.8 sccm of TMAto the reaction furnace, and 4) purging excess TMA from the reactionfurnace by 25 sccm of N₂ for 60 seconds. The sequence from 1) to 4) wasrepeated 290 cycles, until the deposited layer achieved suitable layerthickness of over 100 Å. FIG. 15 shows the XPS depth profile of the SiCfilms deposited at 400° C., including the O, Al, Cl impurities. FIG. 16shows the film thickness (hollow) and refractive indices (solid) basedon the measurement position. The graph illustrates the higher refractiveindex obtained with PCDS+TMA than that with HCDS +TMA. The films havingthe higher refractive index (i.e., from PCDS+TMA) may be more dense thanthose with the lower refractive index (i.e., from HCDS+TMA), which mayenhance wet etching resistivity.

Example 10 Low-T PEALD of Si(C)N

FIG. 17 is a schematic diagram of deposition apparatus used for thetesting of Example 10. The apparatus includes a reactor 100 containing awafer stage 101. The wafer is transferred to the wafer stage 101 by loadlock chamber 102, which is connected to pump 108. A showerhead 103 islocated in the top of the reactor 100, and plasma may be generated bythe RF generator 106. A dry pump 105 removes the contents of the reactor100.

The disclosed Si-containing precursor is introduced to the reactor 100from delivery device 200 via line 201. An inert gas 300, such as Ar, isdelivered to the delivery device 200 via line 301. The inert gas 300 mayalso be delivered to the reactor 100 via line 302.

A nitridation gas 400, such as N₂, is introduced to the reactor 100 vialine 401. The inert gas 300 may also be delivered to the nitridition gas400 via line 303.

One of ordinary skill in the art will recognize that lines 201, 301,302, 303, and 401 may include numerous pressure gauges, check valves,valves, and pressure regulators and that additional lines for pressureregulation or by-pass flow have not been included in order to simplifythe drawing.

Si(C)N films were deposited at low temperature using pentakis(dimethylamino) disilane (Si₂H(NMe₂)₅) as a Si source and a nitrogencontaining reactant via a plasma enhance ALD process using thedeposition apparatus of FIG. 17. The process was done on 6″ Si wafer,under direct plasma mode. The pressure in the reaction furnace of FIG.17 is controlled at 1 Torr, the temperature varied from 200° C. to 400°C., and 500 sccm of Ar was continuously flowing. The deposition processincludes the following steps: 1) introducing a N₂ plasma pulse (100 W)of 100 sccm of N₂ to the reaction furnace for 7 seconds, 2) purging thereaction furnace by 500 sccm of N₂ for 3 seconds, 3) introducing 1 sccmof Pentakis(dimethylamino)disilane to the reaction furnace for 5seconds, and 4) purging excess Si precursor from the reaction furnace by500 sccm of N₂ for 5 seconds. The sequence from 1) to 4) was repeated500 cycles until the deposited layer achieved suitable layer thicknessof over 100 Å.

FIG. 18 shows the XPS depth profile of the Si(C)N film deposited at 275°C., which exhibited a formation of SiN, with ˜11% C and ˜2% O in thefilm. FIG. 19 shows the Si exposure time of deposition rate (square) andrefractive index (circle) at a 10 second (solid) and 20 second (hollow)purge time. The graph, in case of 10 sec purge time, illustrates thatthe deposition rate increased corresponding to Si exposure time, but therefractive index remained stable at 1.8 to Si exposure time. Howeverwhen the Si purge time increased from 10 sec to 20 sec, for the case of20 sec Si exposure time, the deposition rate decreased from 0.5 Å/cycleto 0.42 Å/cycle, and the RI increased from 1.78 to 1.81, which maydemonstrate an inefficient purge time for the longer pulse process.

It will be understood that many additional changes in the details,materials, steps, and arrangement of parts, which have been hereindescribed and illustrated in order to explain the nature of theinvention, may be made by those skilled in the art within the principleand scope of the invention as expressed in the appended claims. Thus,the present invention is not intended to be limited to the specificembodiments in the examples given above and/or the attached drawings.

We claim:
 1. A thermal vapor deposition method of depositing a siliconfilm on a substrate, the method comprising: a) setting a reactorcontaining the substrate to a temperature ranging from approximately550° C. to approximately 800° C. and a pressure ranging fromapproximately 0.1 to approximately 100 Torr (13 Pa to 13,332 Pa); b)introducing a vapor of pentachlorodisilane into the reaction chamber toform the silicon film on the substrate.
 2. The method of claim 1,further comprising introducing an inert gas.
 3. The method of claim 2,wherein the inert gas is N₂.
 4. The method of claim 1, furthercomprising introducing a reducing gas.
 5. The method of claim 1, whereinthe silicon film contains between approximately 0 atomic % and 5 atomic% C; between approximately 0 atomic % and 1 atomic % N; and betweenapproximately 0 atomic % and 1 atomic % Cl.
 6. The method of claim 5,wherein the silicon film is an amorphous silicon film.
 7. The method ofclaim 5, wherein the silicon film is a polysilicon film.
 8. The methodof claim 3, wherein the silicon film contains between approximately 0atomic % and 5 atomic % C; between approximately 0 atomic % and 1 atomic% N; and between approximately 0 atomic % and 1 atomic % Cl.
 9. Themethod of claim 8, wherein the silicon film is an amorphous siliconfilm.
 10. The method of claim 8, wherein the silicon film is apolysilicon film.